3D Powder Layer Compression for Reusable Unprocessed Granules

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Solution Overview

Problem

Existing methods for manufacturing three-dimensional shaped objects using granulated powder face challenges in reusing unused material due to changes in granular form during compression, leading to inefficient material utilization.

Innovation Solution

A device and method that utilize a table with a layer formation portion to stack granulated powder, a compression unit to selectively crush powder in designated regions, and a control unit to manage the compression process, allowing for the reuse of unprocessed powder by maintaining its granular form in unused regions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire layer of granulated powder is pressurized to consolidate the layer, then volume contraction accompanying sintering is suppressed, but the granular form of granulation is changed and the configuration material cannot be reused

Engineering Contradiction:

Improveconsolidation of layerVSAvoidreusability of configuration material

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The layer of granulated powder is divided into a processing region (where powder is crushed and consolidated) and a non-processing region (where powder remains uncrushed and reusable). The compression unit selectively compresses only the processing region, leaving the non-processing region untouched, thus enabling material reuse while maintaining consolidation where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the layer are given different properties: the processing region undergoes compression to achieve consolidation and suppress volume contraction, while the non-processing region maintains its original granular state for reuse. This local differentiation allows simultaneous achievement of consolidation and material reusability.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If granulated powder is used as configuration material, then the three-dimensional shaped object can be manufactured by stacking layers, but the entire layer must be pressurized which changes the granular form

Engineering Contradiction:

Improvelayer stacking processVSAvoidgranular form preservation

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The layer is segmented into processing and non-processing regions, allowing the ease of manufacture through layer stacking to be maintained while preserving the granular form in the non-processing region for future reuse.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The compression is applied locally only to the processing region where consolidation is needed, while the non-processing region retains its granular quality for reuse, thus resolving the contradiction between manufacturing ease and material preservation.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If valuable or expensive material is used as configuration material, then high-quality three-dimensional shaped objects can be manufactured, but unused material cannot be reused due to compression-induced granular changes

Engineering Contradiction:

Improvequality of three-dimensional shaped objectVSAvoidreuse of valuable material

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

By segmenting the layer into processing and non-processing regions, valuable material in the non-processing region is preserved in its original granular form and can be reused, while the processing region receives the necessary compression for high-quality manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of discarding or reprocessing all compressed powder, the invention recovers the uncrushed granulated powder in the non-processing region, allowing valuable material to be reused in subsequent manufacturing cycles, thus reducing waste and cost.

Inventive Principle:

Principle #34Discarding and recovering

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the consolidation of three-dimensional shaped objects with fine particles while allowing for the reuse of granulated powder, thereby optimizing material utilization and reducing waste.

Implementation Method 1

a compression unit configured to compress a first region in the layer

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

a method for manufacturing in which a three-dimensional shaped object is manufactured by stacking a layer of powder, as a configuration material of a three-dimensional shaped object, for laser sintering in a container as a table, and by irradiating a portion corresponding to the three-dimensional shaped object in the layer with a laser

Methodology Applied

Scientific EffectLaser sintering: Laser

Data Source

PatentUS12240059B2Device for manufacturing three-dimensional shaped object and method for manufacturing three-dimensional shaped object

Publication Date: 2025.03.04 SEIKO EPSON CORP

AI summary

A device for manufacturing a three-dimensional shaped object includes a table on which a layer of granulated powder is stacked, a layer formation portion that forms the granulated powder on the table into a layer having a predetermined thickness, a compression unit configured to compress a first region in the layer, a processing unit that processes the formation region of the three-dimensional shaped object in the layer, and a control unit that controls the compression unit to form the first region in which the granulated powder are crushed, and the second region in which the granulated powder are not crushed.